All purpose carpet dye kettle



April 18, 1961 w, cUTTEN ETAL 2,979,934

ALL PURPOSE'CARPET DYE! KETTLE 2 Sheets-Sheet 1 Filed Oct. 20, 1958 FIG. 2.

INVENTORS WILLIAM K. CUTTEN JOHN MCNUTT BY$ ATTX w. K. CUTTEN ETAL 2,979,934

ALL PURPOSE CARPET DYE KETTLE 2 Sheets-Sheet 2 I I H II HI Hum HH Illlll l ll'l zj ji/m/ April 18, 1961 Filed Oct. 20, 1958 INVENTORS ILLIAM K. CUTTEN JOHN McNUTT United States Paten .v F

ALL PURPOSE CARPET DYE KETTLE William K. Cutten, Allentown, and John McNutt, Blue Bell, Pa., assignors to James Lees and Sons Company, Bridgeport, Pa., a corporation of Pennsylvania Filed Oct. 20, 1958, Ser. No. 768,270 Claims. (Cl. 68- 177 This invention relates to edge control devices for running webs of material and more particularly to an edge control device for feeding more than one length of carpet simultaneously through a dye kettle or other liquid treating mechanism.

Where it is desired to feed narrow lengths of pile fabric through and into a liquid treating apparatus such as a dye kettle, it is found highly desirable to control the alignment and feed position of the fabric. the width of the fabric has been substantially the same as the width of the kettle. This, of course, has necessitated designing and maintaining a series of dye kettles each being of the required width to receive the particular roll of fabric being treated. As the range of fabric widths increases, it will be evident that an increasingly large number of various width dye kettles would be required because wider fabrics cannot be handled in a narrow dye kettle satisfactorily, and because of the inadequacy of the edge control devices in wide kettles, narrow fabrics could not be properly treated in wide kettles.

In the operation of a dye kettle of the type shown and described herein, it is customarily the practice to feed a long length of fabric into the kettle and then sew the ends together temporarily. In this way a long, endless roll of fabric is gradually drawn into and out of the 'dye liquor in which the fabric is stored in folds. The present invention enables a wide dye kettle to treat satisfactorily two lengths of pile fabric running side by side in the kettle and to maintain the proper edge control for each length despite the fact that it is impossible to position any edge control mechanism inside the dye kettle proper and the usual enclosure.

A primary object of the invention, therefore, is to provide edge control apparatus in a multi-web treating device in which the control mechanism for the plurality of webs is all positioned exteriorly of the treating chamber.

A further object of the invention is to provide an edge control device having a plurality of web control elements independently and variably driven from the same atrial end of each element.

A further object of the invention is to provide an inboard journal for edge control devices which will not be subject to harmful effects of the treating liquids.

Further objects will be apparent from the specification and drawings in which:

Fig. l is a side view of a dye kettle equipped with the edge control device of the present invention,

Fig. 2 is a front view of the dye kettle of Fig. 1,

Fig. 3 is an enlarged detail of a portion of Fig. 1,

Fig. 4 is a front view of the structure of Fig. 3,

Fig. 5 is a top view of the selectively driven rolls or elements for controlling the lateral feeding'position of the fabric webs into the dye kettle,

Fig. 6 is an enlarged sectional detail as seen at 66 of Fig. 3,

Fig. 7 is a section as seen at 7-7 of Fig. 6,-

Heretofore 2,979,934 Patented Apr. 18,

Fig. 8 is a section as seen at 88 of Fig. 6, and Fig. 9 is an enlarged sectional detail as seen at 9-9 of Fig. 6.

The invention comprises essentially the provision of two independently controlled and driven feed rollers for a plurality of fabric webs and means located entirely at one end of the rollers for controlling the relative rotation of the rollers in accordance with the position of the fabric over the rollers. The invention is particularly useful in a wide dye kettle having four rollers which control two simultaneously running webs of fabric fed into the kettle. The control mechanism for each pair of rollers is positioned completely outside of the enclosed dye kettle where it is not capable of being contacted or harmed by strong dye liquors or other liquids used in the treating of the fabric.

For purposes of convenience, the present invention will be illustrated and described in conjunction with a dye kettle of the type used for piece dyeing tufted, woven, and knitted pile fabrics. However, it will be understood that the invention has much wider application and may be employed in any situation where it is desired to 'pendently driven spiral rolls 18, 19, 20, and 21. The

rolls operate in pairs so that rolls '18 and 19 control the travel of fabric F and rolls 20 and 21 control the travel of fabric G both being fed simultaneouslyto the same dye kettle 15. The rolls 18-21 are journaled on a series of brackets 22, 23, 24, 25, and 26 which are in turn mounted on a shaft 27 supported in pillow blocks 28 and 29 at either side of the dye kettle. The pillow blocks are in turn mounted on suitable supporting platforms 30 and 31 (Fig. 2). Particular attention is directed to the inboard bearing 35 for the four rolls 18-21. Due to the standard width of the dye kettle, this bearing 35 is limited insofar as axial length is concerned. The design of this hearing is quite critical since it is subjected to considerable radial load and the usual metallic bearing materials are unsatis factory due to high deterioration in the presence of corrosive action of the dye liquors. The same applies to each center roll bearing 35a and 35b. p In general, each pair of rolls 18, 19 and 20, 21 is driven at the same peripheral speed through their associated shafts and sleeves as will be described in detail hereinafter. However, if the fabric tends for any reason to shift laterally on either pair of rolls 18,19 or 20, 21, automatic mechanism is provided to drive the rollsat differential speeds to re-align the fabric lengths and maintain them between the sensing fingers 36, 37, 38 and 39. Fingers 36 and 37 are positioned to detect lateral movement of fabric F, whereas fingers 38 and 39 are sensitive to lateral deviation in the travel of fabric G, When fabric F, for example, moves to the right, as seeri in Fig. -5, finger 36 will be displaced, thus closing a circuit to motor 40 which accelerates the speed of this motor with regard to motor 41, and moving thefabric web back to the left to run substantially between the fingers 36 and 37. The same action takes place at the other side of the dye kettle in conjunction with fingers 38 and 39 and motors 42 and 43.

Referring now to Fig. 6,. the constructional details of the dual edge control mounting will be clearly appar; ent. Roller 18 comprises a' cylindrical outer shell 45 having a plug or cap 46 welded in each end. A helica l rod 47 is wrapped and welded around the periphery oi shell 45 with a righthand or Z twist as shown in Fig. 5. The shell 45 and its associated ends 46 are rigidly secured to a central inner sleeve 48 which is mounted atone end on bearing or bushing 49 preferably made of a graphite impregnated rubber-like material. Bushing 49 is journaled in bearing 35a and also journals the drive shaft 50 on which the roller 19 is mounted. Roller 19 is identical in construction to roller 18 except that the helical coil 51 on roller 19 is wound opposite hand from the coil 47 on roller 18. Additionally, there is no necessity for an internal sleeve on roller 19 since it is keyed or rigidly secured to shaft 50. Since roller 19 isdrivingly connected to shaft 50 at its inboard end, it is not essential that shaft 50 be carried completely through the bore of roller 19. We, therefore, interrupt shaft 50 within the bore of rollers 19 and 26 and use a stub shaft 50a as shown clearly in Fig. 6. The outboard end of shaft 50a is journaled in a graphite impregnated rubber-type bushing 52.which is mounted in one side of the center bearing 35. At the opposite end sleeve 48 is journaled in pillow block 53 by means of an annular ball bearing assembly 54 having an inner race 54a secured to sleeve 48 by setscrew 56. The outer race 54b of bearing 54 is mounted in the upper housing of pillow block 53 and retained therein by means of a snap ring 57. Sleeve 48 extends through pillow block 53 and is provided with an oil seal 58 in such a manner that the sleeve and consequently roller 18 may be driven from motor 40 through chain 60 and sprockets 61, 62, the latter of which is secured to sleeve 48 by means of setscrcws 63, 63. Shaft 50 extends completely through the outer terminus of sleeve 48 and is journaled therein by means of a double row annular ball bearing assembly 65 having an outer race 65asecured to sleeve 48 by means of collar 66, cap screws 67, 67, and a retaining plate 68 held by screws 69, 69. The collar 70, which is secured to shaft 50 by means of setscrew 71, maintains the shaft 50 in proper axial position in the bore of sleeve 48 Shaft sprocket 75 is secured to the shaft by means of a key 76 and setscrew 77. The control of roller 19 is accomplished from motor 41 through chain 78 and sprockets 79 and 75. It will be seen' that is sprockets 79 and 61 have the same pitch diameter, and if sprockets 62 and 75 have the same pitch diameter as each other, rollers 18 and 19, being of the Same diameter, will turn with equal peripheral speeds provided the speed of motors 40 and 41 is the same.

In operation, the actuation of sensing finger 36 as described above increases the relative speed of motor 41, thus increasing the peripheral speed of roller 19 with respect to roller 18, and tending to shift the carpet or web laterally to the left. Conversely, if and when sensing finger 37 is actuated, the speed of motor 40 and the relative peripheral speed of roller 13 with respect to roller 19 are increased, thus tending to shift the running carpet laterally to the right.

The electrical connections will be described in conjunction with the operation of the invention, although it will be understood that the showing of the connections and the sensing elements in the drawings is schematic only. The sensing elements and electrical connections to the control motors form no part of the invention per se but, of course, are necessary to complete an operative device.

Referring to Figs. and 6, it will be noted that if the carpet or running web F moves to the right sufficiently to displace sensing finger 36, this displacement closes a higher speed circuit through leads 80, 81, and switch 82 to motor 41. Motor 41, as explained above, drives roller 19 so that the increase in speed of roller 19 gradually shifts the'running carpet F to the left. Conversely, when sensing finger 37 is displaced to the left in Figs. 5 and 6, a circuit through leads 80, 83, 84, and switch 85 is completed to motor 40, thus increasing the speed of motor 40 and roller 18. In view of the righthand helical convolutions of the coil 47, this 4 increased speed increment eventually returns the web F to a center position, thus permitting both sensing elements 36 and 37 to remain in a normal, unbiased position not in contact with either edge of web F. The main current for operating motors 40 and 41 is supplied through primary leads S6 and 87-running directly to the motors. The identical control then occurs for motors 42 and 43 which independently vary the speed of rollers 20 and 21 through sprockets 9i) and 91 in the same manner as described above. The mounting and drive for rollers 20 and 21 is by means of sleeve 92 and shaft 93, the outboard end of the latter or, if preferred, a stub shaft 93a corresponding 'tostub shaft 50a being journaled by a similar rubber bushing 94. v 1 7 It has been found in practice that the necessary relative differences in peripheral speeds of rollers 18, 19 and 20, 21 varies very little and the shifting action of the web' due to the differential speed is extremely gradual because both rollers are being driven in the same direction at all times. For this reason it has been found that hunting is not a problem since there is little tendency for the running web to shift back and forth.

It will thus be understood that complete relative control of both carpets F and G is achieved when the cover 16 of the dye kettle is closed and without introducing any electrical control elements inside the kettle.

The present device is rugged, satisfactory to construct, and provides complete control of the carpet or fabric travel from a point outside the enclosed dye kettle.

Having thus described our invention, we claim:

We claim:

1. In apparatus for simultaneously liquid treating a plurality of webs of textile fabric running side by side, an enclosed kettle having a series of side members, a central fabric drawing roller journal mounted within said kettle, at least two external fabric drawing roller journals mounted outside the kettle side members and laterally aligned with each other and the central journal, intermediate fabric drawing roller journals mounted within the kettle between each external journal and the central journal and in alignment with said other journals, a pair of inner spirally surfaced fabric drawing rollers each journaled at one end on opposite sides of said central fabric drawing roller journal and at their other ends in the intermediate journals, a pair of outer spirally surfaced fabric drawing rollers journaled between each outer fabric drawing roller journal and the adjacent intermediate journal, a drive shaft for each of the inner fabric drawing rollers extending through its adjacent outer fabric drawing roller, a motor connected to each of said drive shafts externally of the kettle, independent drive means for each of the outer spirally surfaced fabric drawing rollers, a motor connected to each of said independent driving means externally of the kettle, and means responsive to the lateral position of fabric webs passing over the rollers for relatively varying the speed of the motors at each side of the kettle.

2. "In liquid treating apparatus for textile fabrics, a kettle in which a pair of webs of textile fabric is adapted to be emersed, a lid for said kettle, two pairs of roller means journaled inside the kettle for moving each of said webs, a'first roller of each of said pairs having a surface formed of spiral convolutions of one hand, a second roller of each pair having a surface formed of spiral convolutions of the opposite hand, a driving con nection for the inner one of each of said pairs of rollers extending through the center of the outer one of each pairs of rollers, externally mounted drive means con nected, to each of said driving connections, four edge contact members inside the kettle positioned in alignment with the edges of the webs, and electrical connections responsive to movement of the edge contact members for varying the relative speed of the external drive means to thereby control the lateral position of each web on its associated pair of rollers.

3. Ida dye kettle having at least twopairs of spiral rollers over which running lengths of fabric to be dyed are adapted to be fed, a center bearing for each of said pairs of rollers within the dye kettle, an inboard bearing for each of said pairs of rollers within the dye kettle, a third bearing for said pairs of rollers outside the dye kettle, a center shaft journaled in at least two of said bearings and extending through one of said rollers, the inner roller of each pair being rigidly secured to said shaft, a motor mounted outside the dye kettle, driving connections between said motor and said shaft including a pair of sprockets and a chain, a second roller of the pair journaled on the shaft, a sleeve secured to said second roller and extending outside the dye kettle and surrounding the shaft, means including an annular ball bearing for retaining the shaft and the sleeve in relative axial alignment with respect to each other, a second motor mounted outside the dye kettle, driving connections between said second motor and the sleeve including two sprockets and a chain, and control means for each of the motors for selectively increasing the speed of one of the motors in accordance with the lateral position of the fabric running over the rollers.

4. A roller assembly for a dye kettle comprising two bearingswithin the kettle, one bearing outside the kettle,

\ a first roller journaled in the outside bearing and one of the inside bearings, a second roller journaled in the two inside bearings, a driving connection between said first roller and an external sprocket outside the kettle, a driving connection between the second roller and another sprocket outside the kettle, means for retaining the driving connections in relatively fixed axial alignment, and opposite hand spiral convolutions on each of said rollers.

5. Apparatus in accordance with claim 2 in which the inboard bearings comprise graphite impregnated bushm-gs.

References Cited in the file of this patent UNITED STATES PATENTS 1,680,190 Wikle Aug. 7, 1928 1,857,941 Corley May 10, 1932 2,133,823 McCellan Oct. 18, 1938 2,577,195 Johnson Dec. 4, 1951 2,806,694 Penman Sept. 17, 1957 

